| Summary: |
First unpainted slush molded TPU with very low gloss and
first TPU with dramatically increased airbag deployment range.
Assembled part cost savings: 5% due to elimination of paint. |
| Most Innovative Feature: |
First unpainted slush molded TPU with very low gloss
(1.0-1.5 vs. 5-7) and first TPU with dramatically increased airbag
deployment range(-40C to +107C vs. -30C to 85C). |
| Other Innovative Features: |
Allows mold-in-color that meets OEM's emerging
"rich" looking interior, achieving improved harmony. The new
material also has 25% improved cycle time. |
| What Forming Process? |
Slush molding. |
| First Time Process Used: |
Yes. |
| Previous Process: |
Most previous slush molded TPU's and PVC require paint due
to performance requirements. Previous
materials do not achieve low gloss. Previous TPU did not have to meet the
more stringent occupant out of position airbag requirements. |
| Tooling Innovations: |
Tool preparation chemistry & process coupled with tool
maintenance chemistry & process were additionally developed. Cleaning
and mold release chemistry were also developed to maintain consistency of
gloss. |
| New Material Developments: |
Patented new chemistry and new polymer processing were
required to simultaneously achieve low gloss, elimination of paint, and an
airbag deployment window of -40C to 107C. |
| Weight Savings: |
None. |
| Cost Savings: |
Elimination of paint provides assembled part cost reduction
of 5%. |
| Cost Avoidance: |
Slush molding cycle time is reduced by 25%. |
| Direct Consumer Benefit: |
Customer sees interior as substantially improved (rich
look, soft touch) versus previous interior.
The system also achieves improved performance at both the high and
low ends of the temperature range. Fit
and finish issues are eliminated by this technology. |
| Translates to Other Vehicles?: |
Can be translated to other OEM's and vehicle lines. |
| Safety Benefits: |
System allows airbag deployments to occur over the largest
temperature range of any commercial material. |
| Environmental Benefits: |
Material is environmentally recyclable without harmful
emissions. No paint system
allows for easier recycling than painted systems (no paint stripping
required). Volatile organic
compound emissions are also eliminated. |
| Additional Comments: |
The polymerization process for preparing the TPU is also
unique. The new
polymerization process generates a more consistent molecular weight which
results in cycle time reduction. |
